Zippered two-shell EVA hard case, 26 mm closed. All contents sit in one 14 mm die-cut foam tray in the base: a spring-hinged pop-up rack for ten 1 mL syringes, three lying troughs for 3 mL vials and two spare-needle slots under a third strap, a needle-clipper recess and a zip mesh swab pocket, with a silicone prep mat under the tray. The 5.7 mm lid carries an inscribed brand strip and a zip mesh pocket holding a 2 mm gel cold sheet and a prescription card. Reference geometry is in the accompanying 3D file (GLB / OBJ).
| Item | Spec | Note |
|---|---|---|
| External, closed | 200 × 186 × 26 mm | Includes zipper band; excludes pull tab |
| Base shell height | 20.3 mm | Outer, floor to rim |
| Lid shell height | 5.7 mm | Outer, floor to rim |
| Wall thickness | 2.5 mm | Molded EVA over 0.8 mm PP floor stiffener, both shells |
| Edge radius | R1.25 mm | Floor-to-wall edge, both shells; reads as a soft edge, not a bumper |
| Corner radius, plan | R10 mm | Outer; inner follows at R7.5 |
| Internal cavity | 195 × 181 mm | Base usable depth 17.8 mm; lid 3.2 mm |
| Open angle | 110° stop | Fabric spine limits lid; free-standing when open |
| Target weight, empty | ≤ 220 g | Inserts, rack, mat and cold sheet included |
| Layer | mm | Note |
|---|---|---|
| Base wall | 2.5 | EVA over PP stiffener |
| Base lining | 0.3 | Tricot, bonded to the floor |
| Silicone prep mat | 0.8 | Under the tray; pull tab at the front rib |
| Base foam tray | 14.0 | Rack recess, vial, needle, clipper and swab cutouts through to the mat |
| Clearance to base rim | 2.7 | Straps (2.6 mm) live here, flush with the rim |
| Lid wall | 2.5 | |
| Lid liner | 0.3 | Tricot, bonded |
| Prescription card | 0.8 | Bottom of the mesh pocket |
| Gel cold sheet | 2.0 | Removable; lies over the tray when closed |
| Clearance to lid rim | 0.1 | Mesh face compresses |
| Total | 26.0 |
Rack, flat: 2 mm plate + Ø9 barrel + 2.6 mm strap = 13.6, 0.4 below the tray top. Vials (Ø16.5) lie on the mat, top 0.3 below the base rim. Spare needles (Ø14 shield) lie on the mat, top at the foam. Clipper (13 thick) and swab stack (8 × 1.3) stay below the foam. Nothing crosses the parting line.
| Part | Material | Finish / colour |
|---|---|---|
| Shells (2) | Compression-molded EVA 2.5 mm over 0.8 mm PP floor stiffener, matte PU-coated polyester outer | Matte black, fine grain; no gloss, no exterior stitching |
| Interior lining | Brushed polyester tricot, bonded to shell | Charcoal |
| Base tray insert | Closed-cell EVA, 14 mm, die-cut, Shore 35–40 A; through-cut rack recess 122 × 136 | Charcoal, matches lining |
| Syringe rack | 2 mm PP plate 120 × 134 with 11 moulded 4 mm ribs at 13 mm pitch; Ø2.4 steel hinge pin along the far edge with two torsion springs (pops to 22° when the lid releases it); two 14 mm elastic straps | Matte black; front rib orange PMS 1655 C as the lift edge |
| Elastic straps (3) | Woven elastic, 14 mm, 2.6 mm thick, 25 % stretch | Black, single orange stitch line PMS 1655 C along one edge |
| Mesh pockets (2) | Polyester diamond mesh with #3 reverse-coil zipper | Charcoal; orange pull tabs |
| Main zipper | #5 reverse coil, water-resistant tape, single slider, recessed 0.5 mm into the rim | Black tape, no exposed teeth; 22 × 3.5 mm orange webbing pull |
| Cold sheet | Non-toxic gel in TPU film, 186 × 150 × 2 mm | Slate blue; in the lid pocket over the Rx card |
| Prep mat | Platinum-cure silicone, 192 × 178 × 0.8 mm, under the tray; 14 × 8 mm pull tab folded over the front rib | Charcoal, matte, wipe-clean; tab orange PMS 1655 C |
| Needle clipper | Sourced, BD Safe-Clip type, 83 × 32 × 13 mm | White; recess sized to fit, top flush with insert |
| Brand mark | Inscription only, on the interior brand strip (section 05); no exterior logo, patch or bar | Debossed, ink-filled orange PMS 1655 C |
Origin at the cavity centre, X across the width (right positive), Z along the depth (front positive). Cutouts are through the full 14 mm unless noted.
| Cutout | Size | Position | Holds |
|---|---|---|---|
| Rack recess | 122 × 136, R3 | X −33; Z −85.75 … +50.25 | Through-cut. Pop-up rack hinged along the far (−Z) edge; ten 1 mL syringes at 13 mm pitch lying along X, cap toward −X |
| Vial troughs (3) | 46 × 18, R5 | X +64; Z = −76.75, −54.75, −32.75 | 3 mL vials, lying, crimp toward +X: two peptide, one bacteriostatic water |
| Needle slots (2) | 44 × 16, R4 | X +64; Z = −11.75, +8.25 | Spare insulin needles, capped (pen needle or loose needle in its shield), lying along X |
| Clipper recess | 86 × 34, R4 | −49, +70 | Needle clipper, top flush with insert |
| Swab pocket | 90 × 34, R4 | +49, +70 | Zip mesh face stitched to the lining; eight swab sachets in one stack |
Straps: A and B 14 × 132 mm along Z on the rack at X = −60 and −6, over the barrels; C 14 × 104 mm along Z at X = +58 (Z −86.75 … +17.25), across the vial bodies and both spare needles. Stitched at both ends, orange stitch line on top.
| Element | Size | Position | Note |
|---|---|---|---|
| Liner | 193 × 179 × 0.3 mm | Full cavity | Tricot, bonded |
| Brand strip | 187 × 14 × 0.5 mm | Along the far edge, 2 mm from the wall | Level rubberised panel; “FITNESS PROTOCOL” inscribed: debossed 0.3 mm and ink-filled orange PMS 1655 C, 130 mm wide, cap height 9 mm. Interior only |
| Zip mesh pocket | 191 × 159 mm | From the brand strip to the hinge, zipper along the strip edge | Holds, bottom up: prescription card (85 × 54), gel cold sheet; both come out for use |
| Prep mat | 192 × 178 × 0.8 mm | Not in the lid: under the base tray, section 04 | Slides out by its orange tab |
Shells compression-molded over a PP floor stiffener and lined; lining wraps the rim and is caught under the zipper tape. Zipper runs three sides in a 0.5 mm recess so the closed profile is one continuous surface; the hinge side is a 4 mm fabric spine bonded to both shells and sized to stop the lid at 110°. Tray insert is a friction fit with a lift tab at +X. No carry loop, no exterior branding or patch, no exposed metal.
| Check | Requirement |
|---|---|
| Drop | 1.2 m onto concrete, six faces, loaded with dummy glass vials: no shell crack, no vial contact damage |
| Closed fit | Loaded case closes with ≤ 20 N on the zipper; gel sheet rests on straps and vial crowns without deforming the lid (pressure film check); rack returns flat under ≤ 3 N |
| Thermal | Cold sheet frozen 8 h; vial troughs ≤ 15 °C for 3 h at 25 °C ambient |
| Zipper | 5,000 cycles, no coil damage or slider skip |
| Rack hinge | 5,000 open/close cycles; pop angle 22° ± 3° retained, no plate warp |
| Elastic | Retains a Ø9 syringe after 2,000 insert/remove cycles |
| Odour / VOC | Low-odour EVA; no off-gassing at 40 °C, 24 h |
Quotation at 500 / 1,000 / 3,000 units; tooling cost and lead time; one hand sample in the specified colourway; die-line drawing of the tray insert and rack tooling drawing for approval before cutting. Reference 3D geometry is exported in metres, Y-up, part names as listed above.